Flocked elastomeric articles

ABSTRACT

In one embodiment, a flocked article is provided that includes an elastomeric film and a plurality of flock fibers on a flocked surface of the film. The flock fibers are embedded in the film.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefits of U.S. Provisional PatentApplication Ser. No. 60/719,098, filed Sep. 20, 2005, which isincorporated herein by this reference.

FIELD OF THE INVENTION

This application relates generally to designs and transfers andspecifically to a flocked stretchable design or transfer.

BACKGROUND OF THE INVENTION

It is often desirable to decorate clothing or other articles withdesigns that have various surfaces, such as designs that have a flockedsurface such that the surface is fuzzy. Using flocked designs works wellwith clothes or other articles that are not meant to be stretched. Todate, flocked designs have not been used with stretchable articles sincethe flock adhesive layer and, thus, the design, tends to permanentlysplits or cracks, sometimes without recovery, as the material isstretched. This is undesirable since the design becomes severelydeformed. It is also undesirable since the flock fibers may becomedetached from the transfer or design, leaving permanent holes, voids, orgaps in the design. Another undesirable aspect of using flocked designson stretchable articles is that the stretchable article may not reformto its original size and shape near the flocked design due to theadhesive used to keep the flocked design on the clothing or article.

Today's fashions are often characterized by stretchable materials,whether the stretchable material is a knitted material, nylon,polyester, elastic or other material. Thus, a wide market of clothingdoes not use flocked designs because of the undesirable characteristicsassociated therewith. What is needed is a flocked stretchable design ortransfer that can be stretched with the clothing or other article thatwill reform to its original design without loss of design quality oradhesion or integrity of the image.

SUMMARY OF THE INVENTION

These and other needs are addressed by the various embodiments andconfigurations of the present invention. The present invention isdirectly generally to flocked elastic and/or elastomeric films.

In one embodiment of the present invention, flock fibers are embedded inan elastic or elastomeric film by heating the film to a temperatureabove its softening temperature but below its melting temperature andapplying pressure to the fibers. When the film is cooled to atemperature below its softening temperature, the fibers are firmly andpermanently held by the film in the absence of an adhesive. Theresulting flocked interface between the flock fibers and the elastomericfilm can thus be adhesive-free. The film may be contacted with flock byeither direct flocking or flocked transfer techniques.

In another embodiment, an article is provided including:

(a) an elastomeric film having a modulus of elasticity of less thanabout 11.25 lbf, an elongation of at least about 200%, and/or a recoveryfrom elongation of at least about 75%; and

(b) a plurality of flock fibers in contact with the elastomeric film.The interface between the flock fibers and elastomeric film is free ofan adhesive other than the elastomeric film.

The article can have a number of advantages relative to the currentdesign articles. For example, the article can be adhesive-free, therebysaving material and labor costs. The elastomeric film itself acts as theadhesive. The flock is forced into the softened and tacky elastomericfilm under pressure, such as during lamination. When cooled below thesoftening point, the flock is held firmly by the film. When a flocktransfer is used, misoriented fibers are not received by the softenedelastomeric film and stay on the sacrificial carrier. The article,however, may be manufactured using techniques less expensive than flocktransfers. The elastomeric film may be coated with a release adhesive,for example, the release adhesive contacted with flock, and the flocklater pressed into the elastomeric film when the film is thermallysoftened. Alternatively, the flock may be applied to the elastomericfilm while the film is in the softened state. The electrostatic forcemay itself be sufficient to embed the fibers in the film. Finally, theunsoftened elastomeric film, may be electrostatically flocked. Theresidual electrostatic force will hold the flock in position on the filmuntil the film is heated and the fibers pressed into the film.

These and other advantages will be apparent from the disclosure of theinvention(s) contained herein.

As used herein, “at least one”, “one or more”, and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “oneor more of A, B, or C” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B andC together.

The above-described embodiments and configurations are neither completenor exhaustive. As will be appreciated, other embodiments of theinvention are possible utilizing, alone or in combination, one or moreof the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a manufacturing process according to anembodiment of the present invention;

FIG. 2A is a side view of an intermediate flocked heat transfer articleaccording to an embodiment of the present invention;

FIG. 2B is a side view of an intermediate flocked heat transfer articleaccording to an embodiment of the present invention;

FIG. 2C is a side view of a flocked article according to an embodimentof the present invention;

FIG. 3A is a side view of an intermediate direct flocked articleaccording to an embodiment of the present invention;

FIG. 3B is a side view of a direct flocked article according to anembodiment of the present invention;

FIG. 4A is a side view of an elastomeric substrate according to anembodiment of the present invention;

FIG. 4B is a side view of an intermediate direct flocked articleaccording to an embodiment of the present invention;

FIG. 4C is a side view of a direct flocked article according to anembodiment of the present invention;

FIGS. 5A and B, respectively, depict a transfer and an article accordingto another embodiment of the present invention; and

FIG. 6 depicts an article according to another embodiment of the presentinvention.

DETAILED DESCRIPTION

As shown in FIGS. 2C and 3B, a flocked design 200 according to thepresent invention is shown. The design 200 has an elastomeric film 204and a plurality of flock fibers 208 embedded in the film 204. Asubstantial length of each flock fiber is embedded in the film.Preferably, at least about 5%, more preferably at least about 10%, andeven more preferably at least about 15% of the length of each fiber isembedded in the film 204.

The elastomeric film 204 should be durable, thermally stable, and ableto resist the various treatments including but not limited to flockingand/or lamination process, applying chemicals, washing, heating, drying,both during the flocking process and after the design or transfer hasbeen heat applied to the article. The elastomeric material can be of anysuitable composition, such as rubber, polyurethane, and otherelastomers. Particularly preferred elastomers include natural vulcanizedrubber and other elastomers, such as styrene-butadiene copolymer,polychloroprene (neoprene), nitrile rubber, butyl rubber, polysulfiderubber (Thiokol), cis-1,4-polyisoprene, ethylene-propylene terpolymers(EPDM rubber), silicone rubber, (thermoplastic) polyurethane such asSpandex, and polyurethane rubber. As will be appreciated, “elastomers”refer to synthetic thermosetting (typically high) polymers havingproperties similar to those of vulcanized natural rubber, namely theability to be stretched to at least twice their original length and toretract quickly to approximately their original length when released andto un-cross-linked polyolefins that are thermoplastic. “Thermosetting”materials are high polymers that solidify or set irreversibly whenheated. This property is typically associated with a cross-linkingreaction of the molecular constituents induced by heat or radiation. Thematerial may include curing agents, such as organic peroxides or sulfur.Common thermosetting materials include rubber, (linear) polyethylene,phenolics, alkyds, amino resins, polyesters, epoxides, and silicones.Thermosetting materials have a thermoplastic (reversible orun-cross-linked) temperature regime and a thermosetting (irreversible orcross-linked) temperature regime. “Thermoplastic” materials highpolymers that soften when exposed to heat and return to their originalcondition when cooled to room temperature. Examples of thermoplasticmaterials include crude rubber, waxes, polyvinyl chloride, nylons,fluorocarbons, (linear) polyethylene, polyurethane, polypropylene, andcellulosic and acrylic resins.

The elastomeric material is preferably elastic. The term “elastic” asused herein means those materials that have the ability to regain, atleast substantially, their original shape after a load is removed. Theelastic film preferably has a modulus of elasticity of less than about11.25 pounds per foot (“lbf”) (50 N). The modulus of elasticity for thematerial selected is preferably above about 0.5 lbf (2.22 N) (where themodulus is defined as the force required to pull a ¼ inch sample from 3inches to 6 inches). As the modulus of elasticity (Young's Modulus) is afundamental material constant, the modulus is an index of the stiffnessof the material. A higher value of the modulus indicates a more brittlematerial (i.e. glass, ceramics). A very low value represents aelastomeric material (i.e. rubber). The elastic film preferably has anelongation of at least about 200% and more preferably at least about300% and a recovery of at least about 75% and more preferably at leastabout 95%. The recovery is the percent of the film's shape retainedafter the film is stretched to 100% of its original length at a rate of30 inches per minute and the stretched film allowed to retract freelyfor 1 minute. The film preferably has an ultimate tensile strength of atleast about 1,000, more preferably at least about 2,000, and even morepreferably from about 2,000 to about 10,000 psi, and a tear strength ofat least about 200, more preferably at least about 250, and even morepreferably from about 250 to about 700 PLI.

Preferably, the elastomeric material is a substantially transparent,nonwoven, cast or extruded thermoplastic polyester film, with(poly)urethane films being preferred. Even more preferably, the materialis Clarense® by Bemis Associates Inc., Lycra® from Du Pont de NemoursCompany, and Dorlastan® from Bayer and Dureflex® from DeerfieldUrethane.

The elastomeric film 204 preferably is self-supporting and has athickness ranging from about 1 mil to 25 mils and more preferably, fromabout 1 mil to 15 mils.

The flock 208 used in any of the processes discussed herein can be anyelectrostatically chargeable fiber, such as fibers made from rayon,nylon, cotton, acrylic, and polyester. Preferably, the flock preferablyhas a melting and/or softening point that is greater than and isresilient under the temperatures and pressures experienced in designmanufacturing and later application processes to resist softening,deformation, and melting. Due to its low melt point, acrylic flock isundesirable in many applications. Resilient flock, such as rayon, nylon,and terephthalate (e.g., poly(cyclohexylenedimethylene terephthalate)polymer flock, is particularly preferred. In most applications, theflock orientation is at least substantially orthogonal (perpendicular)to the first side of the elastic film.

A method to manufacture the design 200 will now be discussed withreference to FIG. 1. In the method, first and second counter-rotatingrolls 100 and 104 contain flocked carrier sheets that are contacted withthe elastomeric film 204. The contacted assembly formed by flockedcarrier sheets 108 on either side of the film 204 is next subjected toheat and pressure in the lamination station 112. The heat raises thetemperature of the film 204 to a temperature above its softeningtemperature but below its melting temperature. The temperaturepreferably ranges from about 250 to about 400° F. for a time rangingfrom about 5 to about 30 seconds. In this temperature regime, theelastomeric film 204 exhibits adhesive properties. Pressure is appliedto the opposing carrier sheets to embed the free ends of the flockfibers 208 into the film 204. The pressure is at least contact pressureand more preferably is at least about 0.5 psi.

FIGS. 2A-2B demonstrate the various stages of the manufacturing process.FIG. 2A shows the assembly upstream of the station 112. The free ends ofthe flock fibers 208 contact the opposing sides of the film 204 butgenerally do not penetrate the sides. In other words, the fibers 208 arenot embedded in the film 208. As can be seen from FIG. 2A, each flockedcarrier sheet includes a carrier sheet 212 and release adhesive 216. Thecarrier sheet can be any desirable sacrificial carrier, such ascellulose (paper), microporous substrate (such as described in U.S. Pat.No. 6,025,068 and copending U.S. patent application Ser. No. 11/460,493,filed Jul. 27, 2006, each of which is incorporated herein by thisreference), and other known carriers. The release adhesive can be anysuitable adhesive, such as those disclosed in any of the above copendingU.S. application.

FIG. 2B shows the assembly downstream of the station 112. The free endsof the flock fibers 208 are embedded into the film 204 and pass throughthe opposing sides of the film 204. When the temperature of the film 204is cooled to below the film's softening temperature, the fibers arefirmly adhered to the film 204. Thus, the fibers adhere directly to thefilm substrate without the use of a separate permanent or semi-permanentadhesive.

FIG. 2C shows the final design with the carrier sheet and releaseadhesive removed from the flock 208 on either side of the film 204. Theopposing upper and lower sides of the elastomeric film 204 are coatedwith flock fibers.

FIGS. 3A and 3B depict a direct flocked article according to anembodiment of the present invention. FIG. 3A depicts the intermediatearticle 300 upstream of the station 112. The flock 208 iselectrostatically attracted to the film 204, is applied to the film 204using electrostatic direct flocking techniques, and adheres to the upperand lower surfaces of the film 204 in the absence of an adhesive. Tomake this possible, the film 204 is imparted with an electrical chargeopposite to the charge imparted to the adjacent ends of the flock fibers208. The fibers 208 typically have one end positively charged and theother end negatively charged. Consequently, one end is attracted to thecharged film 204 while the other end is repelled by the film 204. Thiscauses the fibers 208 to have a normal or perpendicular orientationrelative to the film surface as shown in FIG. 3A.

FIG. 3B depicts the article 304 downstream of the station 112. As notedabove, pressure and heat are applied to the upstanding flock fibers toforce the fibers down into the film 204 such that the ends of the fibersare embedded in the film.

FIGS. 4A-C depict a direct flocked article according to anotherembodiment of the present invention. FIG. 4A depicts the film 204 priorto direct flocking. The substrate 204 upper and lower surfaces each havea release adhesive layer 216. The release adhesive layer may be appliedby suitable techniques, such as by screen printing. FIG. 4B depicts anintermediate article 400 after direct flocking. The flock fibers areembedded in the release adhesive but not in the film 204. Afterapplication of heat and pressure in the station 112, the fibers areembedded in the film 204. The release adhesive layer 216 is still inplace but covered by the fibers. A user will typically not notice thelayer 216 due to the density and plushness of the flocked surface.

While the direct flocked embodiments can be less expensive than the heattransfer embodiment, the heat transfer embodiment has the advantage ofremoving fibers that are misoriented (i.e., are not normal orperpendicular to the film surface) as they remain on the carriersheet/release adhesive assembly after removal.

In another embodiment shown in FIG. 5, a permanent thermoplastic, hotmelt, or thermosetting adhesive 500 is applied to an unflocked surfaceof the film 204 (which can, for example, be the lower film 204 surface)and the article applied to a substrate 508, such as a textile substrate,using heat transfer techniques. A thermoplastic adhesive 500 ispreferred because thermosetting adhesives are generally brittle andtherefore relatively inelastic. The permanent thermoplastic adhesive 500preferably has a melting point less than the melting point of the film204 to prevent the flock from laying down or becoming misoriented whenthe article is thermally applied to the substrate 508. Preferably, themelting and/or softening point of the adhesive 500 is at least about 25,more preferably at least about 50, and even more preferably at leastabout 75 degrees Fahrenheit less than the melting and/or softening pointof the film 204. Even more preferably, the melting point of the film 208ranges from about 375 to about 400 degrees Fahrenheit, and the meltingpoint of the permanent adhesive ranges from about 275 to about 300degrees Fahrenheit.

In one configuration, the film 500 is a self-supporting, solid adhesivefilm 500, such as described in copending U.S. patent application Ser.No. 09/621,830, filed Jul. 24, 2000; Ser. No. 10/670,091, filed Sep. 23,2003; Ser. No. 10/455,541, filed Jun. 4, 2003; Ser. No. 09/735,721,filed Dec. 13, 2000; and Ser. No. 10/455,575, filed Jun. 4, 2003, eachof which is incorporated herein by this reference. The adhesive film 500is formed before application to the elastomeric film 204, such assolvent casting the film on a sacrificial carrier 504. When the articleis manufactured, the lower roll 104 of transfer 108 is replaced by aroll of the adhesive film 500 and carrier 504, with the free (exposed)surface of the adhesive film 500 facing upwards to adhesively engage thefilm 204. Thus, the transfer and adhesive film 500 are adhered to thecarrier 504 at the same time during lamination. The sacrificial carrier504 supports the solidified film and is removed after application to thefilm 204 and before application to the substrate 508. The removal of thecarrier 504 is shown in FIG. 5B, which shows the article applied to thesubstrate 508 in the absence of the carrier 504.

In another configuration, no permanent adhesive film 500 is required toapply the elastomeric film 204 to a desired substrate. This articleconfiguration is formed by replacing the lower roll 104 of transfer 108with a roll of the substrate 508. Thus, both the flock 208 and substrate508 are adhered to the film 204 at the same time during lamination. Inthis configuration, the upper interface between the flock and film 204and lower interface between the film 204 and substrate 508 are free ofan intervening permanent adhesive.

To adhere to a substrate without a further adhesive, the elastomericfilm is heated to a temperature sufficient to cause the film to becometacky (which is typically above the softening point) but to atemperature that is less than the temperature used to embed the flockfibers in the film. This maintains desired flock fiber orientation andprevents the flock fibers from being dislodged and/or matted down in thefilm.

A number of variations and modifications of the invention can be used.It would be possible to provide for some features of the inventionwithout providing others.

For example in one alternative embodiment, only one surface of the film208 is flocked and the unflocked opposing surface is free of anadhesive. This embodiment may be used to produce a patch.

The present invention, in various embodiments, includes components,methods, processes, systems and/or apparatus substantially as depictedand described herein, including various embodiments, subcombinations,and subsets thereof. Those of skill in the art will understand how tomake and use the present invention after understanding the presentdisclosure. The present invention, in various embodiments, includesproviding devices and processes in the absence of items not depictedand/or described herein or in various embodiments hereof, including inthe absence of such items as may have been used in previous devices orprocesses, e.g., for improving performance, achieving ease and\orreducing cost of implementation.

The foregoing discussion of the invention has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the invention to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of theinvention are grouped together in one or more embodiments for thepurpose of streamlining the disclosure. This method of disclosure is notto be interpreted as reflecting an intention that the claimed inventionrequires more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the followingclaims are hereby incorporated into this Detailed Description, with eachclaim standing on its own as a separate preferred embodiment of theinvention.

Moreover, though the description of the invention has includeddescription of one or more embodiments and certain variations andmodifications, other variations and modifications are within the scopeof the invention, e.g., as may be within the skill and knowledge ofthose in the art, after understanding the present disclosure. It isintended to obtain rights which include alternative embodiments to theextent permitted, including alternate, interchangeable and/or equivalentstructures, functions, ranges or steps to those claimed, whether or notsuch alternate, interchangeable and/or equivalent structures, functions,ranges or steps are disclosed herein, and without intending to publiclydedicate any patentable subject matter.

1-6. (canceled)
 7. A method, comprising: (a) contacting a plurality offlock fibers with a surface of an elastomeric film; and (b) applyingheat and pressure to the flock fibers to embed first ends of the fibersin the elastomeric film.
 8. The method of claim 7, wherein the film instep (b) is maintained at a temperature greater than a softeningtemperature of the film while pressure is applied to the fibers.
 9. Themethod of claim 7, wherein the elastomeric film is a polyesterelastomer, wherein the elastomeric film has a modulus of elasticity ofless than about 11.25 lbf, an elongation of at least about 200%, arecovery from elongation of at least about 75%, an ultimate tensilestrength ranging from about 1,000 to about 10,000 psi, and a tearstrength of at least about 200 PLI, and wherein at least about 5% of thelength of each of the flock fibers is embedded in the elastomeric film.10. The method of claim 7, wherein, in step (a), the surface of theelastomeric film is free of an adhesive.
 11. The method of claim 7,wherein step (a) comprises the substeps: (a1) applying an adhesive tothe surface of the elastomeric film; and (a2) applying the flock fibersto the adhesive, wherein step (b) is thereafter performed to embed thefibers into the elastomeric film.
 12. The method of claim 7, wherein afirst surface of the elastomeric film is in contact with the flockfibers and wherein a second surface of the elastomeric film is incontact with a permanent adhesive, the permanent adhesive having amelting point at least about 50 degrees Fahrenheit less than a meltingpoint of the elastomeric film.
 13. The method of claim 7, wherein theelastomeric film has opposing first and second surfaces and whereinflock fibers are embedded in each of the first and second surfaces ofthe elastomeric film.
 14. The method of claim 7, wherein a first surfaceof the elastomeric film is in contact with the flock fibers, wherein asecond surface of the elastomeric film is in contact with a substrate,and wherein the interface between the elastomeric film and substrate isfree of an adhesive.
 15. The method of claim 7, further comprising: (c)removing a carrier sheet and release adhesive from the fibers after step(b), wherein the carrier sheet and release adhesive are located atsecond ends of the fibers and wherein the first ends are in an opposingrelationship with the second ends. 16-20. (canceled)
 21. The method ofclaim 7, wherein the elastomeric film comprises one of rubber,polyurethane, natural vulcanized rubber, styrene-butadiene copolymer,polychloroprene, neoprene, nitrile rubber, butyl rubber, polysulfiderubber, cis-1,4-polyisoprene, ethylenepropylene terpolymers, EPDMrubber, silicone rubber, thermoplastic polyurethane, and polyurethanerubber.
 22. The method of claim 7, wherein the elastomeric film is aself-supporting film.
 23. The method of claim 7, wherein the elastomericfilm is self-supporting and has a thickness from about 1 mil to about 25mils.
 24. The method of claim 23, wherein the thickness is from about 1to about 15 mils.
 25. The method of claim 7, wherein the flock fibersare orientated substantially orthogonal to the surface of theelastomeric film.
 26. The method of claim 7, wherein the applying ofheat further comprises heating to a temperature from about 250 to about400 degrees Fahrenheit and wherein the applying of pressure furthercomprises a contacting pressure of at least about 0.5 psi.
 27. Themethod of claim 26, wherein the applying of heat has a duration formabout 5 to about 30 seconds.
 28. A method, comprising: (a) contacting aplurality of flock fibers with a surface of a self-supportingelastomeric film; and (b) applying heat to maintain a temperaturegreater than a softening temperature of the self-supporting elastomericfilm and applying pressure to the flock fibers to embed first ends ofthe fibers in the self-supporting elastomeric film, wherein at leastabout 5% of the length of each of the flock fibers is embedded in theself-supporting elastomeric film and.
 29. The method of claim 28,wherein the self-supporting elastomeric film has a modulus of elasticityof less than about 11.25 lbf, an elongation of at least about 200%, arecovery from elongation of at least about 75%, an ultimate tensilestrength ranging from about 1,000 to about 10,000 psi, and a tearstrength of at least about 200 PLI, and the surface of the elastomericfilm is free of an adhesive.
 30. A method, comprising: (a) contacting aplurality of flock fibers with opposing first and second surfaces of aself-supporting elastomeric film, wherein the first and second surfacesare substantially devoid of any adhesive; and (b) applying heat tomaintain a temperature greater than a softening temperature of theself-supporting elastomeric film and applying pressure to the flockfibers to embed first ends of the fibers in the self-supportingelastomeric film, wherein at least about 5% of the length of each of theflock fibers is embedded in the self-supporting elastomeric film,wherein the flock fibers are embedded in each of the first and secondsurfaces of the elastomeric film.
 31. The method of claim 30, whereinthe self-supporting elastomeric film has a modulus of elasticity of lessthan about 11.25 lbf, an elongation of at least about 200%, a recoveryfrom elongation of at least about 75%, an ultimate tensile strengthranging from about 1,000 to about 10,000 psi, and a tear strength of atleast about 200 PLI, and the surface of the elastomeric film is free ofan adhesive.